Section 033543 - Polished Concrete Finishing

Exclusively published and distributed by Architectural Computer Services, Inc. (ARCOM) for the AIA

This Product MasterSpec Section is licensed by ARCOM to PROSOCO, Inc. ("Licensee").

This Product MasterSpec Section modifies the original MasterSpec text, and does not include the full content of the original MasterSpec section.

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SECTION 033543 - POLISHED CONCRETE FINISHING

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To read detailed research, technical information about products and materials, and coordination c hecklists, click on Masterworks/Supporting Information.

Revise this Section by deleting and inserting text to meet Project-specific requirements.

This Section uses the term "Architect." Change this term to match that used to identify the design professi onal as defined in the General and Supplementary Conditions.

Verify that Section titles referenced in this Section are correct for this Project's Specifications; Section titl es may have changed.

PART 1 - GENERAL

0.1 RELATED DOCUMENTS

Retain or delete this article in all Sections of Project Manual.

A. Drawings and general provisions of the Contract, including General and Supplementary Conditions and Division 01 Specification Sections, apply to this Section.

0.2 SUMMARY

A. Section includes polished concrete finishing[, including staining] [and scoring].

1. Concrete for polished concrete, including formwork, reinforcement, concrete materials, mixture design, placement procedures, initial finishing, and curing is specified in Section 033000 "Cast-in-Place Concrete."

B. Related Requirements:

Retain subparagraph below to cross-reference requirements Contractor might expect to find in this Sectio n but are specified in other Sections.

1. Section 033000 "Cast-in-Place Concrete" for concrete not designated as polished concrete.

0.3 DEFINITIONS

Retain terms that remain after this Section has been edited for a project.

Retain "Design Reference Sample" Paragraph below if design reference sample, chosen by Architect duri ng Contract documentation, is proposed.

A. Design Reference Sample: Sample designated by Architect in the Contract Documents that reflects acceptable surface quality and appearance of polished concrete.

0.4 PREINSTALLATION MEETINGS

Retain "Preinstallation Conference" Paragraph below if Work of this Section is extensive or complex eno ugh to justify a conference. Preinstallation conference helps minimize misunderstandings and reviews Pro ject conditions that might lead to significant problems.

A. Preinstallation Conference: Conduct conference at [Project site] .

Retain first subparagraph below if warranted by complexity of design mixtures and quality control of con crete materials.

1. Before submitting design mixtures, review concrete design mixture and examine procedures for ensuring quality of concrete materials. Require representatives of each entity directly concerned with polished concrete to attend, including the following:

a. Contractor's superintendent. b. Independent testing agency responsible for concrete design mixtures. c. Ready-mix concrete manufacturer. d. Cast-in-place concrete subcontractor. e. Polished concrete finishing Subcontractor.

2. Review [cold- and hot-weather concreting procedures,] [curing procedures,] [construction joints,] [concrete repair procedures,] [concrete finishing,] and protection of polished concrete.

0.5 ACTION SUBMITTALS

A. Product Data: For each type of product.

B. Sustainable Design Submittals:

"Laboratory Test Reports" Subparagraph below applies to LEED 2009 for Schools, LEED v4, IgCC, AS HRAE 189.1, and Green Globes. Coordinate with requirements for stains and liquid floor treatments.

1. Laboratory Test Reports: For [stains] [and] [liquid floor treatments], indicating compliance with requirements for low-emitting materials.

C. Polishing Schedule: Submit plan showing polished concrete surfaces and schedule of polishing operations for each area of polished concrete before start of polishing operations. Include locations of all joints, including construction joints.

Delete "Samples for Initial Selection" Paragraph below if colors and other characteristics are preselected a nd specified or scheduled.

D. Samples for Initial Selection: For each type of product requiring color selection.

Retain "Samples for Verification" Paragraph below with or without "Samples for Initial Selection" Paragr aph above.

E. Samples for Verification: For each type of exposed color.

0.6 INFORMATIONAL SUBMITTALS

Coordinate "Qualification Data" Paragraph below with qualification requirements in Section 014000 "Qu ality Requirements" and as may be supplemented in "Quality Assurance" Article.

A. Qualification Data: For Installer.

Retain "Material Certificates" Paragraph below to require submittal of material certificates from manufact urers.

B. Material Certificates: For each of the following, signed by manufacturers:

1. Repair materials. 2. Stain materials. 3. Liquid floor treatments.

0.7 QUALITY ASSURANCE

Field sample panels may be used to verify that Contractor can produce polished concrete of required finis h, color, and consistency of appearance. On simple projects, field samples may suffice and make mockups unnecessary. For more complex projects, field samples may be needed before producing full-scale mocku ps.

A. Field Sample Panels: After approval of verification sample and before casting concrete, produce field sample panels to demonstrate the approved range of selections made under Sample submittals. Produce a minimum of three sets of full-scale panels, approximately 48 by 48 inches (1200 by 1200 mm) minimum, to demonstrate the expected range of finish, color, and appearance variations.

1. Locate panels as indicated or, if not indicated, as directed by Architect. 2. Maintain field sample panels during construction in an undisturbed condition as a standard for judging the completed Work. 3. Demolish and remove field sample panels when directed.

Retain "Mockups" Paragraph below unless field sample panels will suffice and added expense of mockup s is not required. If retaining, indicate location, size, and other details of mockups on Drawings or by inse rts. Revise wording if only one mockup is required.

B. Mockups: Before casting concrete, build mockups to verify selections made under Sample submittals and to demonstrate typical joints, surface finish, tolerances, and standard of workmanship. Build mockups to comply with the following requirements, using materials indicated for the completed Work:

1. Build mockups in the location and of the size indicated or, if not indicated, as directed by Architect. 2. Demonstrate curing, finishing, and protecting of polished concrete.

Retain subparagraph below if the intention is to make an exception to the default requirement in Section 0 14000 "Quality Requirements" for demolishing and removing mockups. 3. Subject to compliance with requirements, approved mockups may become part of the completed Work if undisturbed at time of Substantial Completion.

0.8 FIELD CONDITIONS

A. Traffic Control: Maintain access for vehicular and pedestrian traffic as required for other construction activities.

PART 2 - PRODUCTS

Manufacturers and products listed in SpecAgent and Masterworks Paragraph Builder are neither recomme nded nor endorsed by the AIA or ARCOM. Before inserting names, verify that manufacturers and product s listed there comply with requirements retained or revised in descriptions and are both available and suita ble for the intended applications. For definitions of terms and requirements for Contractor's product select ion, see Section 016000 "Product Requirements."

0.1 STAIN MATERIALS

A. Penetrating Stain: Water-based, penetrating stain with colorfast pigments.

1. Basis-of-Design Product: Subject to compliance with requirements, provide PROSOCO inc., Consolideck GemTone Stain or comparable product by one of the following:

The liquid floor treatment products in subparagraphs below are specific to proprietary polished concrete fl oor systems. Retain one or more of these products if specifying the floor polishing systems.

2. Performance Requirements:

a. First subparagraph below applies to LEED 2009 for Schools Credit IEQ 4.3.Products shall comply with the requirements of the California Department of Public Health's "Standard Method for the Testing and Evaluation of Volatile Organic Chemical Emissions from Indoor Sources Using Environmental Chambers." b. Recipient of Scientific Certification System (SCS) Indoor Air Quality Gold Certification. c. Living Building Challenge Red List Compliant. d. Registered as an approved NSF International/Nonfood Compound Registration. e. Abrasion Resistance: Greater than 50 percent improvement over untreated samples when tested in accordance with ASTM C 1353. f. Achieve "High Traction Range" readings when tested in accordance with ANSI B101.1. g. Coefficient of friction: Greater than 0.60 dry, Greater than 0.60 wet when tested in accordance with ASTM C 1028. h. Adhesion: Greater than 10 percent increase in pull-off strength when compared to an untreated sample when tested in accordance with ASTM D 4541. i. Water Vapor Transmission: 100 percent retained when compared to untreated samples when tested in accordance with ASTM E 96.96M Method B (Water Method). j. UV Stability: No degradation or yellowing of material when tested in accordance with ASTM G 154.

0.2 LIQUID FLOOR TREATMENTS

A. Penetrating Densifier for Polished Concrete Finish: Clear, waterborne solution of inorganic silicate or siliconate materials and proprietary components; odorless; that penetrates, hardens, and is suitable for polished concrete surfaces.

1. Basis-of-Design Product: Subject to compliance with requirements, provide PROSOCO inc., Consolideck LS or comparable product by one of the following:

The liquid floor treatment products in subparagraphs below are specific to proprietary polished concrete fl oor systems. Retain one or more of these products if specifying the floor polishing systems.

First subparagraph below applies to LEED 2009 for Schools Credit IEQ 4.3.

a. Products shall comply with the requirements of the California Department of Public Health's "Standard Method for the Testing and Evaluation of Volatile

Organic Chemical Emissions from Indoor Sources Using Environmental Chambers." b. Recipient of Scientific Certification System (SCS) Indoor Air Quality Gold Certification. c. Comply with national, state, and district AIM VOC regulations and contain 50 g/l or less. d. Living Building Challenge Red List Compliant. e. Registered as an approved NSF International/Nonfood Compound Registration. f. Abrasion Resistance: Greater than 50 percent improvement over untreated samples when tested in accordance with ASTM C 1353. g. Achieve "High Traction Range" readings when tested in accordance with ANSI B101.1. h. Coefficient of Friction: Greater than 0.60 dry, Greater than 0.60 wet when tested in accordance with ASTM C 1028. i. Adhesion: Greater than 10 percent increase in pull-off strength when compared to an untreated sample when tested in accordance with ASTM D 4541. j. Water Vapor Transmission: 100 percent retained when compared to untreated samples when tested in accordance with ASTM E 96/96M Method B (Water Method). k. UV Stability: No degradation or yellowing of material when tested in accordance with ASTM G 154.

0.3 PROTECTIVE TREATMENTS

Retain or delete paragraphs below to suit Project.

Retain "Film Forming Protective Treatments" paragraph below if a general purpose, medium gloss protect ive treatment is required. Use to treat surfaces to increase resistance damage from water, staining, and abr asion.

A. Film Forming Protective Treatments: General purpose medium gloss, film forming sealer to treat surfaces to increase resistance damage from water, staining, and abrasion and is suitable for [natural][stained] polished concrete surfaces.

1. Basis-of-Design Product: Subject to compliance with requirements, provide PROSOCO, Inc.; Consolideck PolishGuard or comparable product by one of the following:

a. Certification: Scientific Certification System (SCS) Indoor Air Quality Gold. b. Compliance with national, state, and district AIM VOC regulations and be 50 g/l or less. c. Living Building Challenge Red List Compliant. d. Achieve "High Traction Range" readings when testing in accordance with ANSI B101.1. e. Coefficient of Friction: Greater than 60 percent dry, 60 percent wet when tested in accordance with ASTM C 1028.

f. Stain Resistance: Achieve limited or no adverse effects when tested in accordance with ASTM D 1038. g. UV Stability: No degradation or yellowing of material when tested in accordance with ASTM G 154.

Retain "Film Forming Protective Treatments" paragraph below if a general purpose, high gloss protective treatment is required. Use to improve the surface sheen, and surface hardness.

B. Film Forming Protective Treatments: General purpose high gloss, premium film forming sealer that contains lithium silicate hardener/densifier to treat surfaces to increase resistance damage from water, staining, and abrasion and is suitable for [natural][stained] polished concrete surfaces..

1. Basis-of-Design Product: Subject to compliance with requirements, provide PROSOCO, Inc.; Consolideck LSGuard or comparable product by one of the following:

a. Certification: Scientific Certification System (SCS) Indoor Air Quality Gold. b. Compliance with national, state, and district AIM VOC regulations and be 50 g/l or less. c. Living Building Challenge Red List Compliant. d. Achieve "High Traction Range" readings when testing in accordance with ANSI B101.1. e. Coefficient of Friction: Greater than 60 percent dry, 60 percent wet when tested in accordance with ASTM C 1028. f. Stain Resistance: Achieve limited or no adverse effects when tested in accordance with ASTM D 1038. g. Adhesion: : >10 percent increase in pull-off strength when compared to an untreated sample when tested in accordance with ASTM D4541. h. UV Stability: No degradation or yellowing of material when tested in accordance with ASTM G 154.

Retain "Penetrating Protective Treatments" paragraph below if a modified silane blend, penetrating clear, reactive oil, and water protective treatment with a VOC content of 400 g/L or less is required. Only specif y over natural, grey polished concrete. Do not use as a protective treatment over the penetrating dye/stain.

C. Penetrating Protective Treatments: Modified silane blend, penetrating clear, reactive sealer with a VOC content of 400 g/L or less shall repel and prevent stains from water and oil substances and is suitable for natural polished concrete surfaces.

1. Basis-of-Design Product: Subject to compliance with requirements, provide PROSOCO, Inc.; Consolideck SLX 100 Water & Oil Repellent or comparable product by one of the following:

a. Compliance with national, state, and district AIM VOC regulations and be 50 g/l or less. b. Achieve "High Traction Range" readings when testing in accordance with ANSI B101.1. c. Coefficient of Friction: Greater than 60 percent dry, 60 percent wet when tested in accordance with ASTM C 1028. d. Stain Resistance: Achieve limited or no adverse effects when tested in accordance with ASTM D 1038. e. Water Vapor Transmission: 100 percent retained when compared to untreated samples when tested in accordance with ASTM E96/96M Method B (Water Method). f. UV Stability: No degradation or yellowing of material when tested in accordance with ASTM G 154.

Retain "Penetrating Protective Treatment" paragraph below if a water-based, low-odor, penetrating oil an d water protective treatment with a VOC content of 100 g/L or less is required. Only specify over natural, grey polished concrete. Do not use as a protective treatment over the penetrating dye/stain.

D. Penetrating Protective Treatments: Water-based, penetrating clear sealer with a VOC content of 100 g/L or less shall repel and prevent stains from water and oil substances for natural polished concrete surfaces.

1. Basis-of-Design Product: Subject to compliance with requirements, provide PROSOCO, Inc.; Consolideck Concrete Protector or comparable product by one of the following:

a. Compliance with national, state, and district AIM VOC regulations and be 50 g/l or less. b. Living Building Challenge Red List Compliant. c. Achieve "High Traction Range" readings when testing in accordance with ANSI B101.1. d. Coefficient of Friction: Greater than 60 percent dry, 60 percent wet when tested in accordance with ASTM C 1028.

PART 3 - EXECUTION

0.1 POLISHING

A. Polish: [Level 1: Matte finish, 100 grit] [Level 2: Low sheen, 400 grit] [Level 3: High sheen, 800 grit] [Level 4: Gloss shine, 3000 grit] [Match design reference sample].

B. Apply polished concrete finish system to cured and prepared slabs to match accepted mockup.

1. Machine grind floor surfaces to receive polished finishes level and smooth [and to depth required to reveal aggregate to match approved mockup].

Retain or delete first subparagraph below to suit Project. 2. Apply penetrating stain for polished concrete in polishing sequence and according to manufacturer's written instructions. 3. Apply penetrating liquid floor treatment for polished concrete in polishing sequence and according to manufacturer's written instructions, allowing recommended drying time between successive coats. 4. Continue polishing with progressively finer-grit diamond polishing pads to gloss level, to match approved mockup. 5. Apply protective treatment in polishing sequence and according to manufacturer's written instructions. 6. Control and dispose of waste products produced by grinding and polishing operations. 7. Neutralize and clean polished floor surfaces.

0.2 STAINING

Retain or delete this article to suit Project.

Concrete must cure prior to application of stain. Some stain colors require longer concrete curing time to meet water-vapor transmission limitations; some colors should not be used for exterior applications. Verif y, with stain manufacturer, the minimum age of concrete for colors required and insert in first paragraph b elow. See the Evaluations.

A. Newly placed concrete shall be at least [21] [30] days old before staining.

B. Prepare surfaces according to manufacturer's written instructions and as follows:

First subparagraph below is generally applicable to new concrete with little surface contamination. More aggressive cleaning, consisting of grinding, sanding, or shot blasting, may be required for older concrete with dense, sealed, or highly contaminated surface.

1. Clean concrete thoroughly by scraping, applying solvents or stripping agents, sweeping and pressure washing, or scrubbing with a rotary floor machine and detergents recommended by stain manufacturer. Rinse until water is clear and allow surface to dry.

Retain one of two options for surface-preparation method in first subparagraph below. Retain first option if penetrating stains are required and acid etching is stain manufacturer's preferred method of profiling co ncrete surfaces. Retain second option for penetrating stain system. 2. Test surfaces with droplets of water. If water beads and does not penetrate surface, or penetrates only in some areas, profile surfaces by [acid etching] [grinding, sanding, or abrasive blasting]. Retest and continue profiling surface until water droplets immediately darken and uniformly penetrate concrete surfaces.

Retain both subparagraphs below if acid etching of concrete surfaces for penetrating stains is required. 3. Apply acidic solution to dampened concrete surfaces, scrubbing with uncolored, acid- resistant nylon-bristle brushes until bubbling stops and concrete surface has texture of 120-grit sandpaper. Do not allow solution to dry on concrete surfaces. Rinse until water is clear. Control, collect, and legally dispose of runoff.

Waterborne stains are pH sensitive. Revise pH value or test method in subparagraph below to suit Project.

4. Neutralize concrete surfaces and rinse until water is clear. Test surface for residue with clean white cloth. Test surface according to ASTM F 710 to ensure pH is between [7 and 8] .

Retain "Scoring" Paragraph below if scoring patterns in concrete surfaces are required. If unstained joints are required or only one color is used, score joints after staining.

C. Scoring: Score decorative jointing in concrete surfaces 1/16 inch (1.6 mm) deep with diamond blades to match pattern indicated. Rinse until water is clear. Score [after] [before] staining.

1. Joint Width: [3/8 inch (10 mm)] .

Retain first paragraph below with either reactive or penetrating stain.

D. Allow concrete surface to dry before applying stain. Verify readiness of concrete to receive stain according to ASTM D 4263 by tightly taping 18-by-18-inch (450-by-450-mm), 4-mil- (0.1-mm-) thick polyethylene sheet to a representative area of concrete surface. Apply stain only if no evidence of moisture has accumulated under sheet after 16 hours.

E. Penetrating Stain: Apply penetrating stain to concrete surfaces according to manufacturer's written instructions and as follows:

1. Apply first coat of stain to dry, clean surfaces by airless sprayer or by high-volume, low- pressure sprayer.

a. Immediately spread the spray applied stain to ensure uniform wetting and color distribution with lightly wet clean microfiber pad with diluted stain.

2. Allow to dry for one hour and repeat application of stain in sufficient quantity to obtain color consistent with approved mockup. 3. Remove excess stain residue by cleaning slab with auto scrubber or dry burnisher. Control, collect, and legally dispose of runoff.

0.3 APPLICATION OF PENETRATING CONCRETE HARDENER/DENSIFIER

A. Apply hardener/densifier at the rate of 500 to 700 sq. ft. (46.5 to 65 sq. m) per gallon with a low pressure sprayer fitted with a 0.5 gpm (0.03 L/s) spray tip per manufacturer's published recommendations[ after final application of the penetrating stain]. (Typically after 200 grit and no later than 400 grit.)

B. Apply sufficient material to keep concrete surface wet for 5 to 10 minute period, without producing puddles.

C. Allow treated surface to dry.

D. Continue progressively polishing floor with required resin diamonds as necessary to produce desired final finish.

0.4 APPLICATION OF PROTECTIVE TREATMENT

Retain one or more of the following four paragraphs to describe application of types of protective treatme nt(s) required.

Retain paragraph below if general purpose, high gloss film-forming protective treatment is required.

A. Application: General purpose, high gloss film forming protective treatment:

1. Apply per manufacturer’s published recommendations to clean, dry slab at the completion of mechanically polishing the slab surface. 2. Lightly wet a clean microfiber pad with protective treatment and wring out excess, leaving the pad damp. 3. Working from one control joint to another, apply a light, fine spray of protective treatment to a small section of the floor using a clean, pump-up sprayer fitted with a 0.5 gpm (0.03 L/s) spray tip, at an estimated coverage rate of 2000 to 3000 sq. ft. (186 to 279 sq. m) per gallon. 4. Using the damp microfiber pad and firm downward pressure, immediately spread the protective treatment to produce a thin, even coating. Spread the product as far as possible while maintaining a wet edge. Properly applied, protective treatment dries quickly. Stop spreading once drying begins. Avoid overlapping. 5. Allow to dry tack free, typically 20-60 minutes. 6. Once dry, high- speed burnish slab surface fitted with manufacturer recommended burnishing pad to increase gloss and to help the treatment fuse and bond with the concrete for increased durability and longevity. Surface temperatures immediately behind the burnisher must achieve 90.5 deg F (32.5 deg C) (Burnish between coats if multiple applications are desired.) 7. Repeat above steps 1 thru 6, as necessary for additional applications of protective treatment, to achieve desired final finish (Maximum 3 coats).

Retain paragraph below if general purpose, medium gloss film forming protective treatment is required.

B. Application: General purpose, medium gloss film forming protective treatment.

1. Apply per manufacturer's published recommendations. 2. Lightly wet a clean microfiber pad with protective treatment and wring out excess, leaving the pad damp. 3. Spray-apply protective treatment using a clean, pump-up sprayer fitted with a 0.5 gpm (0.03 L/s) (conical or fan spray tip at an estimated coverage rate of 400 to 800 sq. ft (37 to 74 sq. m) per gal. Work from one control joint to another. 4. Spread with the damp microfiber pad. Maintain a thin, even coating and wet edge. Stop spreading once drying begins. Do not overlap. Repeat steps 1 thru 4. Two coats are recommended for maximum protection. 5. To increase gloss, wait at least 60 minutes after final coat is applied, then use a high- speed burnisher fitted with a polishing pad. Burnish at a fast walking pace.

Retain paragraph below if a modified silane blend, penetrating oil and water protective treatment with a V OC content of 400 g/L or less is required.

C. Application: Modified silane blend, penetrating clear reactive oil and water protective treatment with a VOC content of 400 g/L or less:

1. Apply per manufacturer’s published recommendations to clean, dry slab at the completion of mechanically polishing the slab surface. 2. Apply in a single application in a well-ventilated area, at an estimated coverage rate of 200 to 600 sq. ft. (18.5 to 54 sq. m) per gallon. Use enough material to keep the surface wet for about a minute before penetrating. Do not atomize. 3. Remove all puddles thoroughly per manufacturer’s recommendations until protective treatment completely penetrates the surface. 4. Wipe down excess with a clean, absorbent towel. 5. Do not burnish slab.

Retain paragraph below if a water-based, low odor, penetrating oil and water protective treatment with a VOC content of 100 g/L or less is required.

D. Application: Water-based, penetrating oil and water protective treatment with a VOC content of 100 g/L or less:

1. Apply per manufacturer’s published recommendations to clean, dry slab at the completion of mechanically polishing the slab surface. 2. Apply saturating application at an estimated coverage rate of 400 to 800 sq. ft. (37 to 74 sq. m) per gallon. Do NOT atomize. 3. Even out all puddles with a microfiber applicator before material has a chance to fully dry. Do not burnish slab.

0.5 SLAB PROTECTION

A. Protect finished floors to prevent damage including staining, gouges and scratching by construction traffic and activities until possession.

B. Do not drag or drop equipment or material across the slab which will scratch or chip it.

C. Inspect tires for debris prior to use on slab. Remove embedded items which may cause damage to floor slab.

D. Clean up spills on slab immediately. Provide cleaning chemicals and absorptive materials.

E. Develop a concrete protection procedure which addresses the following procedures:

1. Communication of protection plan to subcontractors and vendors. 2. Procedures for cleaning up slab spills, including use of and availability of cleaning chemicals and absorptive materials at Site.

F. Provide a clean slab using concrete maintenance cleaner within an auto scrubber, equipped with soft nylon brushes, in accordance with manufacturer's recommendations.

0.6 FINISHING REQUIREMENTS

A. Appearance:

1. Interior exposed colored finished slab areas must consist of the following:

2. Slab surface must meet the desired sheen and color, as discussed in Pre-Installation meeting and be consistent with approved Mock-up.

END OF SECTION 033543

POLISHED CONCRETE FINISHING 033543 - 13